Corrosion resistance behavior of enhanced passivation Cr-modified rebars and their service life prediction based on Monte Carlo simulation

This work investigates enhanced passivation and corrosion resistance of various Cr-modified rebars compared to carbon rebar. It also evaluates their service life through time-varying probability analysis based on Monte Carlo simulation, combined with the parameters obtained from sampling and testing reinforced concrete mortar samples exposed to various marine conditions over 5 years. The results show that the free energy required for oxide thickening of rebar decreases from 20.12 kJ/mol to 9.25 kJ/mol as the Cr content increases from 5 % to 11 % (wt.), which facilitates the developed Cr-modified rebars rapidly form a passive film, exhibiting a chloride threshold level 6-14 times higher than that of carbon rebar. In the harshest marine splash zone, sea sand concrete with Cr11 rebar ensures a theoretical 50-year service life, contrasting sharply with the much shorter lifespan estimated at 5-6 years for carbon rebar. The corrosion rate of Cr-modified rebars was notably lower than that of the carbon rebar, and the Cr oxides/hydroxides facilitate the transformation of FeO(OH) with larger volume expansion to Fe3O4 with smaller volume expansion, reducing from 130 mu m in HRB to 70 mu m in the case of the thinnest Cr11 rebar. The thin and dense rust layer of the developed rebars is advantageous in blocking Cl- and guarantees a smaller volume expansion of structure even if the rebars are corroded. This study underscores the suitability of Cr-modified rebars for sea sand concrete structures and sheds new light on rebar-reinforced concrete structure developments toward eco-efficient and sustainable infrastructures.